Method for processing raw sugarcane maximizing the preservation of policosanols during production of a natural sugarcane juice-based product

ABSTRACT

A method for processing sugarcane juice from raw sugarcane stalks to produce various forms of a natural sugarcane juice product preserves policosanols naturally occurring in the raw sugarcane stalks, resulting in policosanol-rich natural sugarcane juice-based products such as a drinking beverage, a concentrated sweetening agent, and a nutraceutical product. The method may include steps of providing sugarcane stalks having high policosanol concentrations; extracting sugarcane juice from the sugarcane stalks via a series of roller mills; filtering the extracted sugarcane juice; stabilizing the pH of the juice in a non-acidic solution of calcium hydroxide; flocculating the sugarcane juice to remove undesirable impurities; optionally, evaporating the sugarcane juice to form a policosanol-rich sugarcane juice concentrate and extracting the sugarcane juice concentrate from the evaporator.

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application is a continuation of co-pending U.S. patent applicationSer. No. 16/163,365, filed on Oct. 17, 2018 (now U.S. Pat. No.10,493,121), which is a continuation-in-part of co-pending U.S. patentapplication Ser. No. 15/803,037, filed Nov. 3, 2017. The entire contentsof both priority applications are incorporated-by-reference herein.

FIELD OF THE INVENTION

The present invention relates generally to sugarcane processing. Morespecifically, the invention pertains to large-scale commercialprocessing of raw sugarcane to produce shelf-stable naturalsugarcane-based products for human consumption therefrom whilemaximizing the preservation of the raw sugarcane policosanols in theconsumable products.

BACKGROUND OF THE INVENTION

The production of crystallized sugar from raw sugarcane is well known.Furthermore, the development of equipment and associated processes forproducing sugar from sugarcane stalks has been extensive. Generally,sugar product is produced from a naturally occurring liquid containedwithin the cells of raw sugarcane stalks.

In many places throughout the world, and especially in Latin America,this naturally-occurring juice contained in the cells of sugarcanestalks is highly regarded as a beverage. In Latin America, this naturaljuice product is commonly referred to as “guarapo.” The term “guarapo,”which carries the unmistakable sonority of its Quechuan origin, hasbecome part of the Spanish lexicon to identify and define arguably themost pleasant and truly popular beverage in South America. Fresh guarapohas long been regarded as a healthy beverage which, in addition toproviding thirst-quenching refreshment, is believed to have attributesthat improve and enhance sexual performance. In fact, songs written bygrateful Latin Americans having firsthand knowledge of its gifts havebecome an integral part of Latin American folklore.

The present applicant, in his issued U.S. Pat. No. 6,245,153 (the entirecontents of which are incorporated-by-reference herein) taught animproved method for processing raw sugarcane to produce a consumablesugarcane juice, which overcame significant shelf-life limitations ofthen state-of-the-art sugarcane processing methods. Prior to applicant'saforementioned patented invention, there were no known methods forefficiently producing a natural guarapo product having an adequate shelflife to support commercial distribution thereof. In his '153 patent, thepresent applicant teaches a novel method for producing a stabilizednatural sugarcane juice product having an adequate shelf life to enablecommercial distribution, without requiring addition of unnaturalchemical additives, such as acids, during juice processing.

Since the time of applicant's initial invention (i.e. as disclosed inapplicant's '153 patent), there has been a dramatic increase in theoccurrence of dangerously high blood cholesterol levels in humans. Infact, the Centers for Disease Control and Prevention (i.e. the CDC)currently estimates that 73.5 million adults in the United States alone,or 31.7% of the adult population of the United States, have unhealthylow-density lipoprotein (LDL) cholesterol levels, which the medicalcommunity has well established cause a host of health-related problemsin humans. Furthermore, the CDC has indicated that only 29.5% (i.e. lessthan one-third) of adults with high LDL cholesterol have the conditionunder control. People with high total cholesterol levels haveapproximately twice the risk of heart disease as people with ideal totalcholesterol levels.

The pharmaceutical industry has addressed the high-cholesterol problemby continuing to develop a host of cholesterol-lowering drugs known as“statins,” including those sold under the brand names LIPITOR,PRAVACHOLD, CRESTOR, ZOCOR, LESCOL and VYTORIN, to name just a fewexamples. Statins are a class of medicines that are used to lower bloodcholesterol levels by blocking the action of an enzyme in the liver thatis necessary for making cholesterol. Cholesterol is necessary for normalcell and body function, but above normal, or high, LDL and totalcholesterol levels can lead to atherosclerosis, a condition in whichcholesterol-containing plaques build up in the arteries and block bloodflow. By reducing blood cholesterol levels, statins reduce the risk ofchest pain (i.e. angina), heart attack, and stroke. However, there arenumerous well-documented risks and side effects associated with suchpharmaceutical statin drugs. Most people who take statins haveundesirable side effects, including, but not limited to, headaches,pins-and-needles sensation, abdominal pain, bloating, diarrhea, nausea,and skin rashes. Furthermore, it has been found that some statin drugsmay impair memory and increase the risk for development of cataracts, inaddition to causing more serious side effects such as liver failure andskeletal muscle damage. Additionally, a significant segment of thehigh-cholesterol population is advised against taking statins, includingpeople with progressive liver disease, and pregnant and breast-feedingwomen (or those intending to become pregnant).

Concurrently, there has been an increasing awareness throughout themedical community that policosanol, a naturally-occurring ingredient ofraw sugarcane, has shown growing promise as an effective remedy for thetreatment of unhealthy elevated blood cholesterol levels in humans.Researchers have found that policosanols contained in raw sugarcanestalks are remarkably effective and very safe for reducing levels oflow-density lipoprotein (LDL), a component of cholesterol that is knownto cause a host of health-related problems at elevated levels inindividuals. While policosanol is a naturally-occurring component ofsugarcane, chemically speaking, it is completely unrelated to sugar.Sugar and policosanol just happen to come from the same plant. Theeffectiveness of policosanol in the treatment of high cholesterol levelshas proven to be so remarkable that initial estimates of the recommendeddaily intake of policosanol required to efficiently and effectivelyreduce above-normal LDL and total cholesterol levels is miniscule.

Policosanol is a type of alcohol. More particularly, “policosanol” isthe collective name referring to a group of related solid alcohols (i.e.long-chain primary aliphatic saturated alcohols). Policosanol is knownto improve blood lipids, and research studies documenting its highlybeneficial effects on human cholesterol levels are continually beingpublished. Medical research and studies have proven that policosanolreduces low-density lipoprotein (LDL)—commonly referred to as “badcholesterol”—while simultaneously increasing high-density lipoprotein(HDL)—commonly referred to as “good cholesterol.” Additional benefits ofpolicosanol in the treatment of high cholesterol and a host of otherhealth-related issues, as well as an in-depth description of howpolicosanol functions to provide such incredible health benefits, may befound, for example, in an Internet article available atwww.life-enhancement.com/magazine/article/710-policosanol-improves-every-measure-of-blood-cholesterol)and entitled: Policosanol Improves Every Measure of Blood Cholesterol,the entire contents of which are incorporated-by-reference herein.Ongoing medical and scientific research and corresponding studiesstrongly suggest that policosanol is more highly effective thansynthetically-derived pharmaceuticals for treating high blood pressure.Furthermore, a particular policosanol compound, known as “octacosanol,”has been found to provide additional health benefits, including treatinginsomnia caused by stress, improving athletic performance, and treatingsymptoms of Parkinson's disease, in addition to having anti-cancerproperties (e.g., reduced/slowed tumor growth).

Significantly, octacosanol is the most prevalent policosanol componentoccurring naturally in epicuticular sugarcane stalk wax. Policosanol isa mixture of essential alcohols isolated from sugarcane wax (Saccharumofficinarum L.) that consists of different components, with octacosanolrepresenting 66% (or almost two-thirds) of such policosanol components.

Consequently, the ability to efficiently and effectively process avariety of highly-stable sugarcane juice products for human consumptionwhile maximizing the preservation of policosanols in the raw sugarcanebeing processed has the potential to provide a means of enablingindividuals with high cholesterol levels to consume such a small dailyquantity of such a product that the respective corresponding sugarintake would be well within the maximum sugar intake recommended by theWorld Health Organization (WHO), which has recommended a maximum dailysugar intake for adults of five percent (5%) of total daily caloricintake. For a normal weight adult, that is about 25 grams of sugar perday.

Unfortunately, the development of an efficient, repeatable,cost-effective commercial method for maximizing the extraction ofpolicosanols from raw sugarcane during production of a stable naturalconsumable sugarcane juice product has proven elusive. Accordingly,there has been a long felt, yet unmet, need for a repeatable, reliable,and cost-effective method of processing raw sugarcane to produce ahighly stable policosanol-rich consumable sugarcane juice product on acommercial scale. Such a method would provide a means for producing anatural cholesterol-lowering consumable product at such a low cost thatit could be made readily available to all individuals; particularly, themillions of people that currently do not have the financial means toafford existing pharmaceutical drugs. Furthermore, such a method wouldprovide a healthy alternative to drugs manufactured by thepharmaceutical industry that are known to have negative health sideeffects.

Accordingly, applicant began experimenting with alternative sugarcaneprocessing methods for producing a variant of his stabilized sugarcanejuice product, which maximizes the preservation of the policosanolsnaturally stored in the cells of the pre-processed raw sugarcane used toproduce his shelf stable sugarcane juice. Following extensive researchand experimentation, applicant has discovered a variation of thesugarcane processing method originally disclosed in his above-identifiedissued U.S. patent (U.S. Pat. No. 6,245,153), which overcomes theaforementioned challenges by providing a repeatable, efficient, andhighly cost-effective process for the commercial production of apolicosanol-rich, stable, consumable product from raw sugarcane.Furthermore, applicant's process enables the production of suchpolicosanol-rich, stable, consumable products in a variety of formsincluding, for example, a ready-to-drink (i.e. potable) juice beverage,a concentrate that can be used as a sweetener to be added to an existingbeverage, and a highly-concentrated nutraceutical, to name just a few.

SUMMARY OF THE INVENTION

The present invention relates to a method for processing a shelf stablesugarcane juice product from raw sugarcane, which preservesnaturally-occurring policosanols found in raw sugarcane, as well as tothe products produced by the inventive method. The method incorporates asugarcane juice extraction process that preserves the natural flavor ofthe juice, prevents natural fermentation of the processed juice andpreserves the natural color of the juice. Furthermore, the methodenables the bottling and long-term storage of a variety of forms ofpolicosanol-rich sugarcane juice products, and has been adapted forproducing large volumes of juice product, in a variety of forms, forlarge-scale commercial production and distribution.

These and other objects are achieved by the method of the presentinvention. In a general exemplary implementation of the method,sugarcane juice is extracted from manually-harvested high sucrosecontent sugarcane sticks using a roller mill tandem. Juice extractedfrom the mills is filtered and then stabilized at a pH of about 7.4 to7.6 through the addition of Calcium Hydroxide. Subsequently, the juiceproduct may be heated from a temperature in the range of about 20° C. to30° C., to a temperature not exceeding 90° C. Subsequently, the juiceproduct may be subjected to a series of clarification processes in whichnatural or industrial additives may be. Subsequently, the juice productmay be concentrated through an evaporation step to form a sugarcanejuice concentrate. Subsequently, the concentrate may be furtherclarified and further concentrated to a Brix of about 75+/−5 degrees.

These and other aspects, features, and advantages of the presentinvention will become more readily apparent from the attached drawingsand the detailed description of the preferred embodiments, which follow.

BRIEF DESCRIPTION OF THE DRAWINGS

The preferred embodiments of the invention will hereinafter be describedin conjunction with the appended drawings provided to illustrate and notto limit the invention, in which:

FIG. 1 is a schematic illustration of an exemplary implementation of amethod for producing a consumable policosanol-rich sugarcane product, inaccordance with the present invention;

FIG. 2 is a schematic illustration of a sugarcane juice clarifyingapparatus that may be employed with the method of the present invention;

FIG. 3 is a schematic illustration of an apparatus that may be usedduring juice clarification sub-steps of the process; and

FIGS. 4A through 4D are a schematic illustration of an exemplarysystem/method for producing a consumable policosanol-richsugarcane-based product, illustrating the addition of surfactants andemulsifiers at particular locations during processing of the rawsugarcane in order to further maximize the relative amount ofpolicosanols in the final product, in accordance with an alternativeimplementation of the present invention.

DETAILED DESCRIPTION OF EXEMPLARY IMPLEMENTATIONS

The following detailed description is merely exemplary in nature and isnot intended to limit the described embodiments or the application anduses of the described embodiments. As used herein, the word “exemplary”or “illustrative” means “serving as an example, instance, orillustration.” Any implementation described herein as “exemplary” or“illustrative” is not necessarily to be construed as preferred oradvantageous over other implementations. All of the implementationsdescribed below are exemplary implementations provided to enable personsskilled in the art to make or use the embodiments of the disclosure andare not intended to limit the scope of the disclosure, which is definedby the claims. For purposes of description herein, the terms “upper”,“lower”, “left”, “rear”, “right”, “front”, “vertical”, “horizontal”, andderivatives thereof shall relate to the invention as oriented in FIG. 1.Furthermore, there is no intention to be bound by any expressed orimplied theory presented in the preceding technical field, background,brief summary or the following detailed description. It is also to beunderstood that the specific devices and processes illustrated in theattached drawings, and described in the following specification, aresimply exemplary embodiments of the inventive concepts defined in theappended claims. Hence, specific dimensions and other physicalcharacteristics relating to the embodiments disclosed herein are not tobe considered as limiting, unless the claims expressly state otherwise.

Referring now to FIGS. 1-3, the method of the present inventiongenerally includes the following steps:

Sugarcane Selection: Initially, it is preferable to select extremelysweet, soft and flavorful varieties of sugarcane which havesubstantially no acidic content. In particular, it is preferred that theraw sugarcane chosen for processing yields a Brix within a range of 18to 28 degrees Brix. It will be apparent to those skilled in the art ofsugarcane processing, that numerous varieties of sugarcane meeting thepreferred standards are available in various regions of the world. Wellknown examples of sugarcane varieties which work well with the processof the present invention include: CCSP2000 CENICANA COLOMBIA SAO PAOLO;CC8568 CENICANA COLOMBIA; CC8592 CENICANA COLOMBIA; MY74275 MAYAGUEZ; CC S P1940 and POJ2878, to name just a few.

Sugarcane Harvesting & Transport: In the majority of sugar mills aroundthe world, burning the standing sugarcane to facilitate cutting andlifting for transport to the mill is common practice. Where mechanicalharvesting is employed and equipment is used for both cutting andlifting, the step of burning is not required. Unfortunately, sugarcaneburning introduces ash byproduct which alters the natural flavor of thesugarcane juice; however , burning i s not required and can beeliminated. Consequently, in the method of the instant invention it isabsolutely imperative to avoid the step of burning, since thisconventionally used step evaporates policosanols and a primary purposeof the present method is the retention of such policosanols. Wheremechanical harvesting is employed and equipment is used for both cuttingand lifting, the flavor or the green leaves is bitter and the tastecontaminates the juice and cannot be removed.

To avoid the need for sugarcane burning, it is preferred that thesugarcane chosen for use with the present invention is manually cutapproximately two inches from the stool, removing all green and dryleaves. It is also preferable that the sugarcane tops, commonly referredto as “cogollos,” are cut off; thereby avoiding the introduction oftheir pasty taste which is difficult to eliminate in processing withoutthe use of chemical additives. It is crucial that the cut cane stalksare not cleaned at this step because the majority of policosanols in rawsugar cane are contained within the outer portion (or cortex) as a waxcontaining upwards of 80 percent (80%) of the policosanols. Furthermore,if the cane is burned then the policosanols are evaporated, completelydefeating the purpose of the invention. As described further hereinbelow, policosanol is extracted from the wax during subsequent rollingoperations. Furthermore, for similar reasons, it is absolutely crucialthat the temperature of the extracted product containing policosanols isnever subjected to a temperature greater than 90° C. This is a crucialdeparture from conventional raw sugarcane processing, and would notoccur to those skilled in the art since heretofore thepreservation/retention of policosanols has not, prior to applicant'sinvention, been a consideration.

Once the sugarcane has been manually cut, the unwashed cut cane shouldbe lifted into a vehicle for transportation to a processing facility.Avoiding mechanical harvesting provides the further benefit of avoidingthe introduction of foreign matter commonly carried into the processingmill along with the sugarcane. The foreign matter, often comprising tenpercent or more of the sugarcane weight, primarily consists of soil,sludge, ash, leaves, minerals and cane tops. The introduction of theaforementioned foreign matter has the undesirable effect of altering thenatural flavor of subsequently extracted sugarcane juice.

Chopping & Juice Extraction: The cut sugarcane stalks are initiallytransferred onto a conveyer table 10 (FIG. 2) where they remainunwashed. This is highly significant and very different thanconventional sugarcane processing wherein sugarcane stalks are washedthoroughly for removal of impurities (without regard to removing thewax). Subsequently, the sugarcane stalks are conveyed through a standardchopping apparatus 20 to reduce the stalks into smaller individualpieces for feeding through a series of roller mills.

The sugarcane juice extracted at each of the mill sites, in the processof the present invention goes directly to the factory to be processedaccording to the invention. It is important that the cane is milled atthe lowest possible rate. In particular, the milling rate is preferablyreduced to approximately 50 percent of the rate used during conventionalsugar production. This reduced rate allows the milling equipment to runwithout stress (i.e. since not at full capacity) so the resultingproduct quality is maximized.

Conventional sugarcane juice extraction methods incorporate hot watermaceration to aid in the extraction process. Thus, the sugarcane shouldbe macerated with clean—preferably treated—hot water. For example, it ispreferred that the water used for maceration have a temperature within arange of about 80 to 90 degrees Celsius.

Macro-Particle Filtration: Initially, the sugarcane juice extracted 30is subjected to a standard filtration process 40 for removingmacro-sized particles from the juice product, as is well known in theindustry. For the purpose of the present invention, the term macro-sizedparticle is used to denote particles having an average diameter on theorder of at least approximately 1.0 to 1.5 microns. Preferably,macro-particle filtration is accomplished by passing the juice extractedthrough a standard steel screen filter having about 300-400 openings/in²followed by passage through a standard vibrating screen filter having1.0 to 1.5 micron diameter holes and a vibration frequency ofapproximately 800 vibrations/minute.

Initial pH Stabilization: Once the macro-sized particles have beensubstantially removed from the juice, the juice is subjected to a pHstabilization step 50. Precise pH control of the sugarcane juice iscritical. The standard procedure in sugar mills is to add CalciumHydroxide (CaOH), also referred to as milk of lime, until the pH levelof the limed juice attains a value in the range of 8.0 to 8.5. Withknown sugarcane juice processes, the pH level of 8.0 to 8.5 ismaintained prior to subjecting the juice to a clarification process,such that the resulting pH level is about 7.0 following clarification.

In the method of the present invention, the quantity of CalciumHydroxide added to the sugarcane juice is limited to an amount requiredto achieve a pH level within a range of about 7.4 to 7.6 and preferablyabout 7.5. Consequently, the quantity of Calcium Hydroxide additive isreduced relative to the quantity typically introduced using existingprocesses. This reduction is critical for maintaining the natural flavorof the sugarcane juice and the policosanol. In general, retaining thenatural flavor of the sugarcane juice in the final product requiresminimizing the quantity of juice additives such as Calcium Hydroxideduring processing. Following the subsequently performed steps of heating60 and clarification 70, the resulting pH level of the sugarcane juiceproduct is maintained at approximately 7.2 to 7.6; optimal for retainingthe natural flavors.

Heating: Following the step of pH stabilization, the juice product isheated 60 from an initial temperature of approximately 26.7 to 29.4° C.,to a temperature of approximately 80° C. to 90° C.; however, in thepresent case it is crucial that the temperature never exceeds 95° C. inorder to prevent the loss of policosanols. Heating may be accomplishedusing a standard heating apparatus as is well known in the industry. Forexample, one well known type of juice heating apparatus adequate for usewith the process of the present invention comprises a vertical orhorizontally disposed steel cylinder having plates at opposite ends forsupporting juice-communicating tubes there between. The flow of juicethrough the series of tubes is controlled by a series of baffles. Lowpressure steam is communicated into the cylinder through a series ofmechanical valves and connectors, arranged such that the steam is flowedthrough a specific path, minimizing the formation of non-condensable gaspockets. The condensate is typically extracted from a lower part of thecylinder via a steam trap.

Initial Standard Clarification: Following the step of heating, the limedjuice product is communicated to a standard clarification apparatus 70,as is well known in the industry. Significantly, as further describedbelow, the present method deviates from the method described inapplicant's previous process (i.e. U.S. Pat. No. 6,245,153) in that, forexample, the Cachaza was discarded during the prior process. In thepresent method, the Cachaza is retained because it contains aconcentration of policosanols to be preserved during the presentprocess. Standard clarification includes the addition of any of a numberof commonly-used industrial flocculates. For instance, CALGON CANE FLOCR-200 and STORKHAUSEN PRAESTOL are two examples of well-known industrialflocculates used for clarification. The flocculates attach to impuritiesin the limed juice and then descend to the bottom of the clarifyingapparatus. With known processes, the Cachaza is extracted throughstandard froth pumps, filtered using a standard filter such as an Oliverfilter, and transferred into storage tanks for subsequent use in rawsugar production. However, in the process of the present invention thejuice obtained following froth pump filtration requires furtherpurification to retain the natural flavor of the sugarcane juice.

With regard to known extraction processes, a quantity of non-sugarimpurities is retained in the juice. The following table illustrates thenon-removed impurities present in the juice following standardfiltration:

TABLE 1 Impurities requiring additional filtration (mg/l) OrganicNon-Sugars Waxy materials (total) 300-800  Waxy materials; hardsugarcane wax 20-50  Waxy materials; soft sugarcane wax 50-100 Waxymaterial; phosphates 5-15 Total Proteins 15-100 Gums 5-50 InorganicNon-Sugar Cations CaO 100-500  MgO 10-80  Fe₂O₃ 5-30 Al₂O₃ 3-20 OrganicComponents Waxy materials 5-15 Protein non-sugars 8-15 Pentosans 3-10Inorganic Components CaO 1-5  MgO 1-5  Fe₂O₃/Al₂O₃ 3-10 P₂O₅ 1-3  SiO₂1-2  Ash insoluble in Hydrochloric acid (clay & sand) 5-20 Very finefiber (“bagacillo”) 15-150

Second Clarification: In a second clarifying step 90, furtherclarification is accomplished using a novel clarifying apparatus toremove the majority of remaining non-sugar impurities in the limedjuice. The general structure of the novel clarifying apparatus, designedfor use with the process of the present invention, is explained in moredetail below.

Natural agricultural flocculate or industrial flocculate is diluted withwater and then added to the juice product in the novel clarifyingapparatus. Examples of natural flocculates that can be used include:GUASIMO (GUAZUMA ULMIFOLIA LAMARK); BALSO (OCHOMA LAGOPUS SW); andCADILLO (TRIUMFETTA LAPPULA L). A natural flocculate would be used toobtain an organic cane juice concentrate.

Prior to being diluted, the natural flocculate is dried and ground intoa fine powder. Preferably, the powdered flocculate is diluted with waterto form a flocculate compound sufficient for removing remainingimpurities in the juice. For example, Applicant has found success mixing225 grams of any of the above natural flocculates in a tank holding 100gallons of water. The flocculate mixture is subsequently injected 80along with the juice into the clarifying apparatus. Applicant has foundthat 10 grams of flocculate per metric ton of juice provides adequateflocculation. The use of natural flocculates helps maintain the naturalflavor of the sugarcane juice. The flocculate mixture combines with theremaining solids and other impurities suspended in the juice to form aglutinous froth, commonly referred to as Cachaza, which floats to thesurface of the juice for easy separation.

Significantly, with the present process the Cachaza is not discardedbecause it contains a concentration of policosanols that are desired tobe retained and preserved in the final product. The Cachaza iscommunicated to special clarifiers for further processing. Inparticular, the Cachaza is subjected to a vacuum press filtrationprocess using a vacuum belt filter press, such as that the TECHNOPULPVacuum Press Filter model VPB260 manufactured by Cordoba FiltrationTechnologies of Ribeirao Preto, Sao Paulo, Brazil. An industrial filterpress is a tool used in separation processes, specifically to separatesolids and liquids. The process uses the principal of pressure drive, asprovided by a slurry pump. A more in depth description of the operationand function of such a vacuum filter press may be found in the technicalpaper TRIALLING A TECHNOPUMP BELT PRESS FILTER AT PIONEER MILL (ProcAust Soc Sugar Cane Technol Vol 25 2013), the entire contents of whichare incorporated-by-reference herein.

Normally, the process can be carried out using any of a variety ofcommercially-available industrial flocculates, including, but notlimited to: TALOFLOTE, manufactured by Tate & Lyle, Incorporated; PCS3106, manufactured by Midland Research Labs; and QUEMIFLOC 900, AH 1000,AP 273, TB 2634, VH 1007, QUEMICLAR VLC, QUEMIFLOC 724, AH 1010, MPM1032, and QUEMIFLOC SE, all manufactured by Quemi International,Incorporated. Furthermore, clarification can be carried out using any ofa number of commercially available anionic and cationic flocculates.

Referring briefly to FIG. 2, the limed juice and flocculate mixture isinjected into the bottom portion of the clarifying tank via conduit 202controlled by valve 204. Subsequently, the mixture is directed into thetank through conduit extensions 205 an angle of approximately 45 degreesto effect circular rotation of the juice mixture in the tank. The lowersection of the tank is provided with a steam coil 226 having a pluralityof openings, preferably ⅛ inch (3.17 mm) in diameter, extendingtherethrough. The rate at which the steam is released should be justadequate to maintain a juice temperature of approximately 70° C. (butnever exceeding 90° C.) and provide heat aeration to the juice to affectflocculate formation and flotation to the surface.

A bubble generating apparatus 208 is provided for enhancing theelevation of froth to the surface of the juice. The bubble generator hasa vapor inlet 208 and valve 210 for controlling the flow of vapor intothe generator. Vapor is released through openings 211 in the generator.A trap 220 is provided at the bottom of the tank for collecting heavysolids that are not carried to the surface. The trap is also used toempty the clarifying apparatus for cleaning.

Upper and lower sets of paddles, 236 and 230, respectively, are rotatedat a rate of approximately 0.5 rotations per minute (rpm), by motorassembly 240. The lower paddles 230 produce a mild stirring motion whichserves to gently stir the juice and effect flocculate formation.Impurity-rich foam froth is formed at the juice surface where it issubsequently skimmed by upper paddles 236 for removal through slurryconduit 224. Preferably, the upper paddles are provided with curved orbowed surfaces to force the froth over the blades. Purified juiceproduct is received through openings 213 in conduit 214 for transportinto overfill tank 242. The purified juice is subsequently communicatedthrough conduit 218 for further processing.

Evaporation & Extraction: Following clarification step 90, the juiceproduct is subject to the step of evaporation 100. The juice product istransferred to an evaporation apparatus through a transfer conduit. Aseries of sugar mill evaporators are employed to incrementally increasethe sugarcane juice concentration. Preferably the juice concentrate issubsequently extracted from the evaporators at a Brix of about 60degrees. Although a significantly higher Brix is possible, this is thepreferred Brix for the additional clarification step 120.

As used herein, the term degrees Brix, represented by the symbol ° bx(and alternatively referred to herein simply as “degrees”) is used toquantify the sugar content of an aqueous solution. More specifically, itis a relative density scale used in the sugar industry to indicate thepercentage (%) of cane sugar (sucrose) by weight (i.e. grams of sucroseper 100 milliliters (ml) of solution). After clarification, theclarified juice is passed to the evaporators to obtain the syrup with adegrees Brix (° Bx) value of 55° Bx (+/−5° Bx). It is critical thatduring the evaporation step the solution never exceeds 70° Bx, in orderto preserve the aforementioned policosanols.

The resulting syrup should have a pH in the range of about 6.0 to 6.4,and its color, if the prior steps were followed precisely, should not bemore than 4500 IU. The measurement of sugar color is an importantfunction of the laboratories of sugar refineries and raw sugar mills,and is also for users of refined sugar products. For example, the ATM X2COLORIMETER, manufactured by Index Instruments Limited ofCambridgeshire, England is an instrument dedicated to this importantquality control function. International Commission for Uniform Methodsof Sugar Analysis (ICUMSA) recommend the use of 420nm as the wavelengthfor color measurements of white and light colored products, and a wavelength of 560 nanometers (nm) for darker sugars. The result is displayedin ICUMSA Color Units (IU) at the wavelength selected. The differenttypes of flocculants should preferably be about double the amountnormally used during conventional sugar cane processing. In particular,it is preferred that the amount of flocculants used (e.g. TETRAFLOC)during this step is double the amount of the instructions, since itworks better. It is also preferable that the flow of the clarifiers doesnot exceed 0.25 (or 25%) of the flow rate normally used duringconventional sugar cane processing.

Third Clarification: Preferably, the juice concentrate is subjected to afurther clarifying step 120. This step is identical to clarificationstep 90. At this step of the process, the juice is preferably maintainedat a temperature of approximately 60° C. Following this clarificationstep, the cane juice concentrate is virtually impurity free; having apurity of approximately 99.9 percent.

Inversion: Following a final clarification step, the clarified may besubjected to an inversion step, wherein the product is communicatedthrough a series of stainless steel tanks (e.g. three inversion tanks)in order to reduce the pH level of the product to about 4.4 to 4.8,using citric acid, phosphoric acid, or a combination of the two.Furthermore, it is preferred that the temperature is maintained within atemperature range of about 50° C. to 60° C. Once this temperature isreached, an enzyme is added at a rate of at least about 0.11 grams pergallon of product (although a greater amount of enzyme may be addedwithout departing from the intended scope of the invention). Forinstance, applicant has found success using 0.25 grams of enzyme pergallon of product at 55 degrees Brix. For example, applicant has foundsuccess using INVERIME 488 (or, alternatively, INVERZIME 482 andINVERZIME 490), all manufactured by Proenzimas SA of Cali, Columbia. Theagitation in the tanks should be constant for a period of about 20 to 30hours, following a predetermined inversion curve continuously.

Vacuum: Following clarification step 120, the concentrate, having a Brixof 60 degrees, is subjected to a vacuum step 120 for further productconcentration wherein the Brix is increased to approximately 75+/−5degrees. It will be apparent to those skilled in the art that this stepcan be performed with a commercially available sugar vacuum pan.

Cooling & Settling: Following vacuum step 130, the sugarcane juiceconcentrate is pumped into tank 140 for cooling to a temperature below54.5° C. The tank is provided with a conical bottom fitted with a smalltrap for solids. Once the sugarcane concentrate having a Brix of 75+/−5degrees is adequately cooled, it can be packed for distribution. Theresulting product has proven to remain shelf stable for a time period ofat least two years.

Referring now primarily to FIG. 1, the following is a list of elementsassociated with reference numbers that are not included in FIGS. 2 and 3(Note: FIGS. 2 and 3 pertain to various sub-steps of the processdescribed herein and relating primarily to the method described inapplicants prior issued U.S. Pat. No. 6,245,123). The followingadditional elements are pertinent to the present method, which relatesto a modification of the original process in order to preservepolicosanols during processing of the raw sugarcane:

Reference Process Step/Element 101 Preparation of Talodura Flocculant102 Tetrafloc 103 Acid 104 Activated Carbon 105 Steam 106 Lime 107 Air108 Water 109 Flocculent 110 Vacuum 111 Hot Water 200 Juice 201 CachazaDeposit 112: Cachaza Disposal Tank 113 Tetrafloc 114 Acid 115 Lime 116Hot Water 117 Flocculent 118 Activated Carbon 119 Steam 120 Air 121Solids to Cachaza Tank 122 Acid and Yeast 123 Water and Steam 124-126Steam 127 Packaging

Significantly, some of the modified features and characteristics of thesystem and method of the present invention have enabled the applicant toachieve a highly-effective, efficient, and cost-effective means for thecommercial production of a policosanol-rich version of the sugarcanejuice product of the present invention.

For example, the cane should be milled at the lowest possible rate.Furthermore, it is important to cease grinding for at least one hourbetween the normal production and sugarcane juice concentrate product,in order to enable cleaning of all the tanks and tubes to ensure thatthere is no contamination of the clean juice with dirty burnt juiceresidue, and for there to be a reduction in the level of the juiceclarifiers.

Maceration: The cane has to be macerated with clean, preferably treatedhot water at a temperature within a range of 80 to 90° C. Applicant hasfound that the policosanols are precipitated at this temperature.Additionally, emulsifiers or surfactants are added depending upon thevariety of cane being processed.

Clarification of the Juice: The pH level must be maintained within arange of about 7.2 to 7.4, which is a departure from conventional rawsugarcane processing. This is due to the cleanliness of the juice thatcomes from the mills. Turbidity is the cloudiness or haziness of a fluidcaused by large numbers of individual particles that are generallyinvisible to the naked eye, similar to some in air. The measurement ofturbidity is a key test of water quality, or other fluid quality. Thepropensity of particles to scatter a light beam focused on them is nowconsidered a more meaningful measure of turbidity in water. Turbiditymeasured this way uses an instrument known in the industry as anephelometer, with the detector set up to the side of the light beam.More light reaches the detector if there are many small particlesscattering the source of the beam than if there are relatively fewerparticles. The units of turbidity from a calibrated nephelometer arecalled Nephelometric Turbidity Units (NTU). To some extent, how muchlight reflects for a given amount of particulates is dependent uponproperties of the particles, such as their shape/geometry, color, andreflectivity. For this reason (and the fact that heavier particlessettle quickly and do not contribute to a turbidity reading), acorrelation between turbidity and total suspended solids (TSS) issomewhat unusual for each location or situation. In accordance with apreferred implementation of the present process, it is important thatthe turbidity is maintained at a level less than 80 NTU.

Clarification of the Sugarcane Syrup: As used herein, the term degreesBrix, represented by the symbol ° bx, is a measurement used to quantifythe sugar content of an aqueous solution. More specifically, it is arelative density scale used in the sugar industry to indicate thepercentage (%) of cane sugar (sucrose) by weight (i.e. grams of sucroseper 100 milliliters (ml) of solution). After clarification, theclarified juice is passed to the evaporators in order to obtain the canejuice with a degrees Brix (° Bx) value of 55° Bx (+/−5° Bx). It iscritical that during the evaporation step the solution never exceeds 90°C., in order to conserve/preserve the aforementioned policosanols.

The resulting syrup should have a pH within a range of about 6.0 and6.4, and its color, if the prior steps were followed precisely, shouldnot be greater than 4500 IU. The measurement of sugar color is animportant function of the laboratories of sugar refineries and raw sugarmills, and is also for users of refined sugar products. For example, theATM X2 COLORIMETER, manufactured by Index Instruments Limited ofCambridgeshire, England is an instrument dedicated to this importantquality control function. The International Commission for UniformMethods of Sugar Analysis (ICUMSA) recommends the use of 420 nanometers(nm) as the wavelength for color measurements of white and light coloredproducts, and a corresponding wavelength of 560 nm for darker sugars.The result is displayed in ICUMSA Color Units (IU) at the wavelengthselected.

In accordance with the method of the present invention, it is preferredthat the relative quantities of the various types of flocculants areabout twice the quantity typically used. Furthermore, it is crucial thatthe flow of the clarifiers does not exceed about 20% of the conventionalclarifier flow rate, and that in the syrup the tetrafloc isapproximately twice the amount conventionally used.

Clarification at Refinery: In the melting tanks, it is preferable toapply twice the amount of active carbon normally used, in order todecolor to the desired ranges to arrive at a final product with thefollowing characteristics:

Color: 2000 IU

pH Range: 6.2 to 6.4

Turbidity: <1400 IU

Brix: 55° Bx (+/−5° Bx)

This step is critical; it is the final step of filtration, and if doneproperly, there will not be any problems with the filtration. Iffiltration is not accurately accomplished, however, the resultingproduct will have too much color and the filters will rapidly becomeclogged. Ideally, the sugarcane juice product should exit theclarification step with a bright glow. If this is not the end result,then the turbidity was likely too high and this will likely causeproblems with the filters used during subsequent filtration.

Filtration of the Sugarcane Juice Product: During this stage of theprocess, it is preferable to incorporate double filtration usingso-called Sparkler-type filters. The Initial (First) Filtration ispreferably accomplished utilizing a layer of DICTALITE 4187. Thisresults in a filtration of 1 micron. If the previous steps are performedproperly, this should result in a flow rate of about 20-25 cubic metersof Product per hour, which is very similar to the flow rate of liquorproduced at the refinery, albeit maybe 20-30% slower, but otherwise anexcellent rate of flow. The target Brix of the syrup being filtered is55° Bx (+/−5° Bx). A Secondary (Second) Filtration is preferablyperformed using a new filtering product called ECOSORB S-426, whichaccomplished all of the beneficial features of DICTALITE product, whileenabling further decolorizing via ionic exchange.

Inversion: Applicant has found great success using a series of threestainless steel inversion tanks, with each of the stainless steelinversion tanks having the capacity to produce five (5) containers at atime. The inversion step must reduce the pH to a level within a range ofabout 4.4 to 4.8, for example, using citric acid, phosphoric acid, or acombination of the two. Furthermore, the target temperature should bemaintained within a range of about 50° C. to 60° C. Once the targettemperature has been achieved, enzyme is added, preferably in a quantityof 0.11 grams per gallon of sugarcane juice concentrate at 55 degreesBrix. By way of example, the present applicant has found success usingan enzyme sold under the tradename INVERZIME 488 (or, alternatively,INVERZIME 482 and INVERZIME 490), all of which are manufactured byProenzimas SA of Cali, Columbia.

Juice Product Concentration: Significantly, through extensiveexperimentation, the present applicant has discovered that it is crucialthat the temperature of the sugarcane juice product never exceeds 90° C.throughout the entire process, in order to ensure maximized preservationof the natural sugarcane policosanols, as previously mentioned herein.Through extensive trial-and-error, applicant has determined thatexceeding this 90° C. temperature causes burning of the product and,significantly, a corresponding loss of policosanols in the product.Again, applicant has determined that the ideal Brix for the syrup formof the policosanol-rich sugarcane-based product produced in accordancewith the present method is 75 +/−5 degrees Brix.

Referring now particularly to FIGS. 4A through 4D, an alternativeimplementation of the system of the present invention similar to thatinitially introduced in FIGS. 1-3, but illustrating the incorporation ofhighly-beneficial preferred surfactant and emulsifier introductionsites, resulting in an improved product quality and improved sugarcaneproduct policosanol content, is presented.

Referring initially to FIG. 4A, an initial sub-component of the systemis shown, including equipment, such as cranes and transportationvehicles shown generally as reference numeral 402. As previouslydescribed hereinabove, preselected sugarcane sticks having high Brix,18+/−10 and policosanol content are introduced to an initial shreddedcane conveyor/conductor, represented generally as reference numeral 404.Conveyor 404 may include a first leveling roller 406, a sugarcane stickshredding apparatus 408, a feeding drum 410, and a cane defibrillationapparatus 412. The shredded cane may be subsequently transferred to asecond, adjacent shredded cane conductor/conveyor 420, which may includea second leveling roller 414 and a third leveling roller 416. The systemis continued in FIG. B, in which the second conductor/conveyor 420 hasbeen reproduced for clarity.

Referring now to FIG. 4B, the shredded sugarcane is processed throughthe entire series of roller mills, denoted 430A through 430 F, whichfunction in conjunction with tanks 440A through 440E, in a manner aspreviously described hereinabove with regard to FIG. 2. Furthermore, amicroscopic bagasse processing system portion, represented by referencenumeral 450, is in communication with diluted juice product tank 432. Asindicated in FIG. 2 for clarity, diluted juice product from tank 432 iscommunicated to heaters 478 (FIG. 4D) Likewise, as further indicated inFIG. 2, juice product from fourth roller mill 430D is communicated tofifth roller mill 430E (FIG. 4C).

Referring now to FIG. 4C, system boilers are represented by referencenumeral 474, and a bagasse storage represented by reference numeral 476.Furthermore, a condenser tank is represented by reference numeral 472,and a maceration tank is represented by reference numeral 470. Thefunction and purpose of the aforementioned components is as previouslydescribed hereinabove with regard to FIG. 2. Significantly, for reasonsdescribed hereinbelow, a quantity of emulsification product (50 ppm to1,500 ppm, depending upon the variety of the cane)—represented byreference numeral 462—is preferably introduced into maceration tank 470.

Referring now to FIG. 4D, a quantity of surfactant (50 ppm to 1,500 ppm,depending upon the variety of the cane), represented by referencenumeral 466 and second quantity of surfactant (100 ppm), represented byreference numeral 464, is introduced into the system as shown.

Significantly, during the process of obtaining sugarcane juiceconcentrate product it is crucial to add quantities of emulsifier andsurfactant products at particular locations during the process, as thesehelp to reduce the viscosity and precipitate the waxes and gums of thesugarcane, which contain policosanols that have not been extracted andprecipitated into the juice by mechanical means during the process. Inparticular, a surfactant (50 ppm to 1,500 ppm, depending upon thevariety of the cane) is added before the first roller mill 430A and tothe band filter 482 of the cachaza. Likewise, an emulsifier (50 ppm to1,500 ppm, depending upon the variety of the cane) is added before thefifth and sixth roller mills, 430E and 430F, respectively, just prior tothe juice clarification process, and just prior to the fifth and sixthroller mills of the molasses clarification. The emulsifier or surfactantis provided at 50 ppm to 1,500 ppm, depending upon the variety of thecane.

Significantly, the juice product of the present invention may beproduced in a variety of forms including, but not limited to, a juicebeverage and a juice concentration, for example, in the form of asweetening agent. Furthermore, the juice product extracted by therolling mills 440A through 440E, prior to being subjected to anyclarification steps, incorporates a policosanol-rich composition thatmay be used in the form of both a juice beverage and a concentratedjuice sweetening agent that may be added to any of a variety of existingliquid beverages.

Juice product extracted from the mills following clarificationincorporates a policosanol-rich composition that may be used in the formof both a juice beverage and a concentrated juice sweetening agent thatmay be added to any of a variety of existing liquid beverages.

Juice product extracted from the mills following clarification andevaporation (i.e. concentrated juice product) incorporates apolicosanol-rich composition that may be used in the form of both ajuice beverage and a concentrated juice sweetening agent that may beadded to any of a variety of existing liquid beverages, and has a shelflife of approximately one month.

Furthermore, applicant has found that an extracted concentrated form ofthe juice product, after being subjected to clarification, filtration,evaporation, and inversion steps of the present method has a shelf lifeof at least approximately two years.

Significantly, applicant has discovered that the method of the presentinvention not only preserves naturally-occurring policosanols from theraw sugarcane but also preserves all of the major (i.e. macro-, micro-,and nano-) nutrients from the raw sugarcane. Accordingly, applicant'smethod may be incorporated for the large-scale commercial production ofsugarcane-based policosanol-rich and nutrient-rich beverages, beverageconcentrates (e.g. for use as sweetening agents and the like), whichprovide the aforementioned cholesterol-reducing and other healthbenefits commonly associated with expensive pharmaceutical products, ata fraction of the cost while eliminating a host of harmful side effectscommonly associated with statins and other cholesterol-reducing drugs.As a result, applicant's method is highly beneficial in that it offers ameans for enabling the treatment of high cholesterol and related healthrisks to potentially tens of millions of individuals around the worldwhom, otherwise, would have no means for seeking help via theconventional healthcare industry.

While the preferred embodiments of the invention have been illustratedand described, it will be clear that the invention is not so limited.Numerous modifications, changes, variations, substitutions andequivalents will occur to those skilled in the art without departingfrom the spirit and scope of the present invention as described in theclaims.

What is claimed is:
 1. A method for processing a quantity of unwashedraw sugarcane sticks to produce a policosanol-rich sugarcane juiceproduct via a sugarcane juice product processing system, the unwashedraw sugarcane sticks each including a sugarcane stalk outer cortexcontaining natural policosanol-rich waxes and minerals, the methodcomprising steps of: shredding the unwashed sugarcane sticks andconveying the shredded and unwashed sugarcane sticks toward a first oneof a series of mechanical roller mills; extracting sugarcane juice fromthe unwashed shredded sugarcane sticks via the series of roller mills,the shredded sugarcane sticks, while being conveyed through the seriesof roller mills, macerated with water having a temperature maintainedbelow a temperature at which dissolution of said policosanol-richnatural waxes and minerals in the sugarcane stalk outer cortex occurs,to produce a volume of water-diluted extracted policosanol-richsugarcane juice product; filtering the diluted extractedpolicosanol-rich sugarcane juice product; stabilizing the pH of theextracted and filtered policosanol-rich sugarcane juice product to astabilized pH level within a pH range of 7.0 to 7.6; heating thepH-stabilized sugarcane juice to a temperature below that at whichevaporation of policosanols from the extracted policosanol-richsugarcane juice product occurs and maintaining that temperature for aperiod of time; clarifying the heated and pH-stabilized sugarcane juice,wherein the heated and pH-stabilized sugarcane juice is flocculatedusing a mixture of water and at least one flocculate product, theflocculated sugarcane juice forming a glutinous froth, the glutinousfroth retained and subjected to further processing in order to preservea rich concentration of policosanols contained therein, thepolicosanol-rich processed froth subsequently reintroduced into thesugarcane juice product being processed; evaporating the clarifiedsugarcane juice product in a manner incrementally increasing both sugarand policosanol concentrations in the sugarcane juice product to createa post-evaporation, policosanol-rich sugarcane juice concentrate havinga Brix value maintained at or below 70° Bx during the entire evaporatingstep; and extracting the evaporated sugarcane juice concentrate fromevaporation apparatus at said post-evaporation Brix value, wherein, thesugarcane processing method maintains a juice product temperature withina temperature range precluding evaporation of policosanols from saidextracted policosanol-rich sugarcane juice product throughout saidprocess.
 2. The method recited in claim 1, wherein the step of providingsugarcane sticks further comprises providing manually-harvestedsugarcane sticks.
 3. The method recited in claim 1, wherein the step ofproviding sugarcane sticks further comprises providing substantiallyacid-free sugarcane sticks preferably having a Brix within a range of 18to 28 degrees Brix.
 4. The method recited in claim 1, wherein the stepof extracting sugarcane juice further comprises passing said sugarcanesticks through said series of roller mills.
 5. The method recited inclaim 4, wherein the step of filtering further comprises filteringsugarcane juice extracted from a first pair of said series of rollermills.
 6. The method recited in claim 1, wherein the step of stabilizingthe pH of said sugarcane juice further comprises stabilizing the pH ofsaid sugarcane juice to a pH of within a range of 7.2 to 7.6
 7. Themethod recited in claim 6, wherein the step of stabilizing the pH ofsaid sugarcane juice further comprises stabilizing the pH of saidsugarcane juice to a pH within a range of 7.4 to 7.6.
 8. The methodrecited in claim 1, wherein the step of extracting said sugarcane juiceconcentrate from said evaporation apparatus at a desired degrees Brixvalue further comprises extracting said sugarcane juice concentrate fromsaid evaporation apparatus such that the sugarcane juice concentrate hasa Brix of about 60 degrees.
 9. The method recited in claim 1, furthercomprising the step of subjecting the concentrate to vacuum such thatthe Brix value of the concentrate is increased to a range of 70 degreesBrix to 80 degrees Brix.
 10. The method recited in claim 1, furthercomprising, following a step of final clarification, a step ofsubjecting the juice product to an inversion process, wherein, prior tosaid inversion process, the sugarcane juice is in a condition adequatefor use as at least one of: a bottled potable drinking juice product anda cane juice component of a sweetening agent.
 11. The method as recitedin claim 10, wherein the step of inversion further comprisescommunicating said clarified juice product through a series of stainlesssteel inversion tanks to effectively reduce the pH level of the juiceproduct using at least one of: citric acid, phosphoric acid, and acombination of citric acid and phosphoric acid.
 12. A method as recitedin claim 12, wherein said step of inversion further comprises steps of:reducing a pH level of the product to within a pH range of 4.4 to 4.8;and maintaining a temperature of said juice product within a temperaturerange of 50° C. to 60° C.
 13. The method recited in claim 1, furthercomprising a step of producing a policosanol-rich sugarcane juice-basedproduct comprising at least one of: a non-concentrated policosanol-richdrinking beverage; a semi-concentrated, policosanol-rich sugarcanejuice-based product adapted for use as a sweetening additive; and ahighly-concentrated, policosanol-rich sugarcane juice-basednutraceutical.
 14. The method recited in claim 1, further comprising astep of producing a dry policosanol-rich sugarcane juice concentrate.